Ridge cap closure system

ABSTRACT

A roof closure system for use with corrugated panel roofs having a ridge cap and ventilated or non-ventilated foam closures permanently attached thereto, the ridge cap and the foam assembled as a ready-to-use single unit. The foam closure is formed a highly mallable foam material such that the closure may be used with any style of corrugated metal roof panels.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention finds use in the field of ridge or roof caps for freestanding structures. More particularly, this invention relates to a ridge or roof cap for structures having corrugated metal roofs and vented or non-vented foam closures.

2. Background

Many types of freestanding structures, particularly commercial buildings, are constructed with roofs formed from corrugated metal panels or sheets. In a building having a peaked or pitched roof, as opposed to a flat roof, a roof or ridge cap is placed at the peak. Depending on the requirements of the building, the ridge cap may serve to assist ventilation in the building in combination with ridge vents in the eaves.

By its very nature, the surface of a corrugated metal panel has a series of repeating troughs and crests. When an object, such the flat attachment portions of a ridge cap are placed on top of such troughs and crests, gaps are formed between the object and the corrugated metal panel. Such gaps are not welcome due to issues of insulation, moisture weathering, and wear from debris collecting in the gaps. It is therefore custom practice to place a strip of foam between the ridge cap attachment portions (flaps) and the corrugated roof panels. The foam is usually contoured on one side to the pattern of the corrugated roof panel and contains an adhesive backing. At the construction site, the adhesive backing on the foam is exposed and the foam is attached to the roof panels. The ridge cap is lined up with the foam closure on the corrugated roof and fastened using conventional means known in the art such as screw, nails, or bolts.

While there is no doubt that prior art foam closure systems are functional, they present several usability problems which can interfere with an otherwise smooth installation in the field. The adhesive backing can sometimes be difficult to expose and, upon exposure, can pick up dirt, dust and other debris from the job site, leading to problems with adhesion and possible premature wear of the foam or the ridge cap. It can also be difficult to line up the exposed adhesive portions of the foam with the roof panels, leading to possible waste of materials and manpower to correct misaligned pieces of foam. Finally requiring corrugated metal panels, foam closures needing to correspond to the shape of the corrugations, and ridge caps, all possibly from separate manufacturers, complicates the ordering and delivery process and leads to clutter on the job site

It is therefore an object of the present invention to provide a roof ridge cap and foam closure that is easy and economical to install in the field.

It is another object of the present invention to provide a roof ridge cap and foam enclosure that reduced the likelihood of collecting unwanted dust, dirt and debris.

It is yet another object of the present invention to provide a foam closure that is able to mate to a wide variety of corrugation styles of metal roof panels so as not to be profile sensitive.

These and other objects of the invention will be apparent to those skilled in the art for the following detailed description of the preferred embodiments of the invention.

SUMMARY OF INVENTION

The invention comprises roof closure system for use with corrugated panel roofs having a a ridge cap and ventilated or non-ventilated foam closures permanently attached thereto, manufactured as a single unit. In the preferred embodiment of the invention, the foam closure is formed a highly mallable foam material such that the closure may be used with any style of corrugated metal roof panels. It is also contemplated that the foam closures attached to the ridge caps may be formed of a shaped foam that corresponds to a particular pattern or style of a corrugated metal roof panel.

BRIEF DESCRIPTION OF THE DRAWING

Specific embodiments of the invention have been chosen for purposes of illustration and description, and are shown in the accompanying drawing, forming a part of the specification wherein:

FIG. 1 is a cross-sectional view of the inventive ridge cap closure system on a metal paneled roof.

DESCRIPTION OF PREFERRED EMBODIMENTS

The ridge cap closure system according to the present invention will be described herein by reference to the accompanying drawing wherein FIG. 1 shows a cross-sectional view of of the inventive ridge cap closure system on a metal paneled roof.

As described in further detail, below, the subject ridge cap closure system 10 is generally comprised of a ridge cap 20 having two or more dependant ledges 22 runing the entire length of both sides of the ridge cap and foam closure strips 24 attached to each of said dependant ledges 22. The ridge cap 20 portion of closure system 10 is constructed of metal conventionally used in metal panel roof buildings, such as galvanized steel, aluminum or copper and is available pre-formed from numerous suppliers or can be bent in situ during the manufacturing process of the entire closure system 10. As shown in FIG. 1, the ridge cap 20 generally is formed in a triangular or peaked shape although a rounded or flatened shape may used, as dictated by the project. Ridge caps normally sold and used in 10′ sections.

In the preferred embodiment of the invention, the foam closure strips 24 are generally formed from a flexible, semi-rigid, cross-linked polyethylene foam, such as is produced by Hibco Plastics, Inc. (Yadkinville, N.C.) or any other foam material used in the art. Depending on the building application, the foam closures 24 can be non-ventilating or ventilating, closed or open-celled. In the preferred embodiment of the invention, the foam closure 24 is formed in a convoluted, egg-crate style and is highly mailable, such that it can conform to any pattern of corrugation of the corrugated roof panels 28. One advantage of using a mailable foam closure 24 over the prior art is that a contractor need only be concerned about ordering the closure system 10 having the appropriate type of ridge cap 20 and not being concerned with ordering the appropriate type of contoured foam to match the style of corregated panels being used on the building project. Futher, mailable foam 24, as used as part of the inventive system 10, offers the added advantage of being able to use different corrugation styles of corruguated panel 28 on the same roof with a continous strip of foam 24. Of course, the closure system 10 of the instant invention functions, albeit less preferrably, using specifically contoured foam matching the contours of the specific corrugated panel 28, as is currently practiced in the art.

The inventive closure system 10 is formed at a factory or other manufacturing facility as a single component rather than a ridge cap 20 and foam strips 24 separately ordered and transported to a construction site and assembled by workers exposing an adhesive backing the foam 24 and adhering the foam to the roof panels. The closure system 10 may be formed as part of a unitary assembly process where the ridge cap 20 and the foam are assembled on the same line with automated means, such as a manufacturing line, or otherwise with minimal human intervention. In an alternative embodiment of the assembly process, the ridge cap 20 and the foam 24 are manufactured in separate facilities, possibly by unrelated manufacturers, brought together at another manufacturing line, an adhesive is applied to the back of the foam 24 which is then precisely mated to the ridge cap 20. In either manufacturing embodiment, the complete closure system 10 is then ready to be transported to a construction site and used, without concern of lining up the foam 24 with the roof panels 28 and subsequently lining up the cap 20 with the roof panels 28 and the foam 24.

Referring again to FIG. 1, a building roof is formed of a series of beams or struts 26, two of which are shown in the cut-away view. A series of corrugated panels 28, typically metal, are affixed to and between the struts 26. The closure system 10 is placed upon the metal panels 28 such that the peak of the ridge cap 20 is aligned with the peak of the roof. The closure system is then attached to the metal panels 28 and the struts 26 by way of fastening means 30 such as screws, bolts, nails, and rivets. Upon attachment, the malleable foam 24 conforms to and fills the various troughs and crests of the corrugated panels 28, forming a tight seal between the ridge cap 20 and the roof panels 28.

In addition to the use with ridge caps 20, the instant invention is adaptable to base plates and eave struts. It should also be noted that the foam may be placed underneath the ridge cap 20 or on top of the base plates or eave struts, depending on the needs of the contractor.

In addition to the structures, sequences, and uses immediately described above, it will be apparent to those skilled in the art that other modifications and variations can be made the method of the instant invention without diverging from the scope, spirit, or teaching of the invention. Therefore, it is the intention of the inventors that the description of instant invention should be considered illustrative and the invention is to be limited only as specified in the claims and equivalents thereto. 

1. A pre-assembled closure system for a corrugated roof, the closure system comprising a ridge cap having a plurality of dependent ledges, each of said dependent ledges having a foam closure permanently attached thereto.
 2. The pre-assembled closure system of claim 1 wherein the foam closure is formed of a malleable foam material whereby the foam closure can conform to a wide variety of patterns of corrugated panels.
 3. The pre-assembled closure system of claim 1 wherein the foam closure is selected from the group comprising ventilating foams and non-ventilating foams.
 4. A manufacturing method of forming a pre-assembled closure system, the method comprising: a) forming a ridge cap for a peaked corrugated roof building, said ridge cap having a plurality of dependant ledges; b) permanently attaching a foam closure to said ridge cap, wherein said attachment is undertaken by automated means.
 5. The method of claim 5 wherein forming the ridge cap and attaching the foam closure are undertaken concurrently on a manufacturing line. 